CYLINDER HEAD (w/o DPF) REASSEMBLY


  1. INSTALL STUD BOLT

    A01KG3GE02
    Text in Illustration
    *a Front Side *b Upper Side
    *c Intake Manifold Side *d Exhaust Manifold Side
    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf, for A and E }
    7.0 N*m  { 71 kgf*cm, 62 in.*lbf, for B }
    15 N*m  { 153 kgf*cm, 11 ft.*lbf, for C }
    20 N*m  { 204 kgf*cm, 15 ft.*lbf, for D }

  2. INSTALL RING PIN

    A01KF9OE03
    Text in Illustration
    *a Less than 5 (0.20) - -

  3. INSTALL NO. 1 WITH HEAD STRAIGHT SCREW PLUG


    1. Apply adhesive to the threads of the screw plugs.

      Adhesive
      Toyota Genuine Adheshive 1324, Three Bond 1324 or equivalent
    2. A01KI2V

      Using a 6 mm hexagon wrench, install the screw plugs.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  4. INSTALL SEMICIRCULAR PLUG


    1. Remove any old packing (FIPG) material.

    2. Apply seal packing to the semicircular plug as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • The semicircular plug must be installed within 3 minutes of applying the seal packing.

      • Prevent seal packing from being stuck to the camshaft thrust groove.

    3. Install the semicircular plug to the cylinder head.

      A01KHXIE03
      Text in Illustration
      *1 Seal Packing - -

  5. INSTALL VALVE STEM OIL O SEAL OR RING

    A01KGDLE01

    1. Using SST, push in a new oil seal.

      SST
      09201-41020

  6. INSTALL INTAKE VALVE

    A01KFAGE01

    1. Install the valve, spring seat, compression spring and spring retainer.

    2. Using SST, compress the compression spring and place the 2 valve spring retainer locks around the valve stem.

      SST
      09202-70020   ( 09202-00020 )
    3. A01KGR8E01

      Using a plastic-faced hammer, lightly tap the valve stem tip to assure a proper fit.

      Note

      Be careful not do damage the valve stem tip.

  7. INSTALL EXHAUST VALVE

    A01KHV5E01

    1. Install the valve, spring seat, compression spring and spring retainer.

    2. Using SST, compress the compression spring and place the 2 valve spring retainer locks around the valve stem.

      SST
      09202-70020   ( 09202-00020 )
    3. A01KFWOE01

      Using a plastic-faced hammer, lightly tap the valve stem tip to assure a proper fit.

      Note

      Be careful not to damage the valve stem tip.

  8. INSTALL VALVE LIFTER


    1. Install the valve lifter.

    2. Check that the valve lifter rotates smoothly by hand.